Cement
Inspections live in production, shutdown workflows digitised, and thousands of parameters captured every month.
Maintenance & reliability execution platform
Your plant already spots the problems. Sysma makes sure they get fixed — and don't come back.
The maintenance & reliability execution platform that closes the full loop — from inspection, permit or alert, through execution and shutdown, to root cause and designed-out failure.
Proven in cement, gas and engineering. Built for heavy industry.
Find it. Fix it. Prevent it.
Inspection Round06:42
Kiln Fan Bearing — vibration
78 °CCoal Mill Belt Drive
NormalGypsum Conveyor Motor
DueCement Mill Lift Motor
CAPA openLive in cement
PTW/LOTO/FLRA live in gas
RCA/CAPA live in engineering
Multi-plant cement rollout underway
The problem
The problem was never spotting the failure. It's getting it fixed — and stopping it coming back.
Operators do the rounds. Sensors flag exceedances. Then findings die in Excel and WhatsApp; corrective work is raised late or never; shutdowns run on spreadsheets and tribal coordination; and the root cause is never captured. That gap is where uptime and money leak out of your plant.
The closed loop
We close the whole loop.
From the moment a problem is found to the moment it’s fixed — and prevented from coming back.
ERP records after the fact. Inspection and alert tools stop at the finding. Big EAMs own the modules the floor never opens. Only Sysma runs the whole loop — where the work happens.
What’s live today
RCA & CAPA live on the floor · FMEA templates deploy-ready · AI assists drafting & RCA, humans approve.
Improve → Prevent is the reliability brain — RCA · FMEA · CAPA · MoC — the part incumbents can’t match.
Business outcome
↓ 18%
unplanned breakdowns
[placeholder — replace with confirmed figure]
Proof
Proven on the floor. Not just in presentations.
Two-plus years live in heavy industry. Real workflows. Real technicians. Real data.
“We’re not replacing Sysma — we’re expanding it across the plant.”
Sysma Dashboard — Live Data
Scheduled Maintenance Compliance
3,002
Assigned
2,459
Closed
283
Expired
Top Failed Assets
- Cement Mill Lifting Motor×3
- Gypsum Belt Conveyor×2
- Coal Mill Fan Bearing×1
12,382
parameters
/ month
12,000+
/ month
Parameters captured
Live
in production
Cement, gas & engineering
180+
templates
FMEA deploy-ready
Whole loop
detect → prevent
On the floor
Gas / Process Industry
PTW, LOTO and FLRA workflows live for governed safe work and audit-ready execution.
Engineering
RCA, CAPA and AI-assisted drafting live for structured closure and repeat-failure tracking.
Cement Rollout
A top-three cement group rollout is underway across multiple plants.
Trusted on the floor across heavy industry
Adani
GSPL
Harsha Engineering
Max Cement
GMDC
Logo files pending — placeholder boxes shown
How you grow
Start where it hurts. Grow into the whole loop.
Start with one workflow — inspection, PTW, shutdown, or RCA/CAPA. Once adoption is visible, expand into the full maintenance and reliability loop. Low-capex wedge to start. No rip-and-replace.
01
Inspect or Permit
Digitize the entry workflow — walk-by inspections or PTW/LOTO/FLRA.
LIVE · cement 2+ yrs · gas permits
02
Execute
Every finding becomes a corrective or preventive order. Run shutdowns on the floor.
LIVE · top-3 cement group implementing
03
Improve
Capture root cause, close formally (CAPA), score risk and design failure out (FMEA, MoC).
LIVE · RCA, CAPA · FMEA ready
04
Predict
Machine Astro sensors + AI diagnostics on the critical assets where it pays.
The apex · added asset by asset
Industries — the two doors
Built for how your industry works.
Most heavy-industry plants enter through one of two patterns. The entry point differs; the loop is the same.
Door 1 · Reliability-led
Reliability-led
Cement · Metals · Mining · Power
Where uptime discipline is everything. Start with inspections, PM, shutdown and recurring-failure control.
Explore industriesDoor 2 · Process-led / PTW-led
Process-led / PTW-led
Oil & Gas · Petrochem · Chemicals · Fertiliser
Where safe-work governance cannot slip. Start with PTW, LOTO, FLRA and permit-linked execution.
Explore industriesWhy Sysma
Why it works where other tools gather dust.
Complements SAP. Does not fight it.
Sysma owns execution on the floor and can feed clean completion data back to SAP or ERP. No ERP surgery. No duplicate system-of-record fight.
Built for the technician's phone.
Mobile-first workflows, evidence capture, approvals, escalation and closure where the work actually happens.
Designs repeat failures out.
RCA and CAPA live on the floor. FMEA templates deploy-ready. AI assists with drafting and RCA support; humans approve.
And when you're ready to predict, not just react —
Machine Astro adds sensor-based prediction on critical assets where prediction pays. Sysma remains the execution layer that turns signals into assigned, verified and closed work.
See what two years on the floor looks like.
Bring Sysma to one section of your plant. Start with inspection, PTW, shutdown or RCA/CAPA. See the workflow on your plant before scaling further.
Low-capex wedge · No rip-and-replace · Built for shopfloor adoption